How Many Boxes Per Hour Can a Robotic Palletiser Handle?

Posted on August 15, 2025 by Granta

Breaking Down the Maths Behind Pick Rates, Patterns, and Productivity

When considering the investment in a robotic palletising system, one of the first questions manufacturers ask is: “How many boxes per hour can it actually handle?”

The answer isn’t a vague estimate—it’s a straightforward calculation based on pick rates and how products are grouped during each pick. While exact performance depends on the product, pallet pattern, and gripper configuration, a few simple examples can give you a clear picture of what’s realistically achievable.

Let’s walk through the maths.

A Conservative Baseline: 330 Picks Per Hour

Although many robotic palletisers are capable of higher speeds, we’ll use 330 picks per hour as a conservative benchmark. This is slower than the typical rate, but provides a solid baseline for planning.

At this pick rate, you only need an average of 2.4 boxes per pick to reach over 790 boxes per hour.  Here’s how different stacking patterns affect that outcome:

Example 1: 10 Boxes Per Layer

Picked in 3 rows (approx. 3–4 boxes per row)

Calculation:
10 boxes ÷ 3 picks = 3.33 boxes per pick on average
At 330 cycles per hours = 3.33 boxes x 250 picks/hour = 1099 boxes per hour

This is a common, efficient pattern where grouped picks deliver strong output while maintaining stack stability.

Example 2: 5 Boxes Per Layer

Picked in 2 rows (e.g. 3 + 2 boxes)

Calculation:
5 boxes ÷ 2 picks = 2.5 boxes per pick on average
At 330 cycles per hour = 2.5 boxes x 330 picks/hour = 825 boxes per hour

Even with smaller layers, efficient pick grouping can deliver well over 800 boxes per hour.

Example 3: 7 Boxes Per Layer

Two options here depending on your tolerance for gaps in the stack:

Option A: Preserve Gaps


Picked in 5 rows

Calculation:
7 boxes ÷ 5 picks = 1.4 boxes per pick on average
At 330 cycles per hour = 1.4 boxes x 330 picks/hour = 462 boxes per hour

Option B: Remove The Gaps

Picked in 3 rows

Calculation:
7 boxes ÷ 3 picks = 2.33 boxes per pick on averageAt 330 cycles per hour = 2.33 boxes x 330 picks/hour = 768 boxes per hour

This example shows how adjusting the pattern can significantly affect throughput—even when the number of boxes stays the same.

Example 4: 20 Boxes Per Layer

Picked in 4 rows (5 boxes per row)

Calculation:

20 boxes ÷ 4 picks = 5 boxes per pick on average
At 330 cycles per hour = 5 boxes x 330 picks/hour = 1650 boxes per hour

High-volume row picks like this show the power of multi-pick grippers and well-optimised stacking logic.

What If the Robot Runs Faster?

In some cases—particularly where boxes are lightweight, uniform, and the gripper is well optimised—robotic palletisers can run at 400 picks per hour or more.

Here’s what that means for each example:

As you can see, the pick grouping and stacking pattern have a much bigger impact on throughput than the robot speed alone.

Key Takeaways

  • Pick rate is only part of the story—the number of boxes per pick has a dramatic effect on total output.
  • Even with conservative cycle speeds, it’s possible to exceed 800 boxes/hour with basic box grouping.
  • Smart gripper design and optimised pallet patterns can more than double throughput in some cases.
  • If you’re stacking lighter products with good box quality, higher pick rates (350–400/hr) are often achievable.
  • Designing your palletising solution around the right stacking strategy can unlock major efficiency gains.

Thinking About Automating?

At Granta Automation, we design intelligent, fully integrated palletising systems tailored to your products, your space, and your output goals. We help you model your throughput with realistic, data-driven expectations—so you know exactly what to expect before the robot is even installed.

  •  Palletiser Feasibility Studies
  •  Gripper Design for Multi-Box Picks
  •  Full System Integration & Controls
  •  Intelligent Stack Pattern Software

Call us on 01223 499488 or helpline@granta-automation.co.uk, to request a free system consultation.

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The True Cost of Workplace Injuries in Warehousing & Manufacturing

Posted on August 13, 2025 by Granta

Across the global industrial landscape, the hum of conveyor belts, the hiss of pneumatic tools, and the clatter of forklift wheels form the everyday soundtrack of warehousing and manufacturing. These environments are engineered for precision and efficiency — yet they remain some of the most hazardous workplaces in the world.

Each year, thousands of workers in the UK and Europe suffer injuries on the job — from repetitive strain and falls to life-altering incidents involving heavy machinery. Behind each incident is a ripple effect of disruption: lost hours, soaring insurance premiums, damaged morale, and often, years-long legal entanglements.

But while the human cost of injury is rightly front and centre, the true financial cost is often underestimated — and poorly quantified. In a sector that thrives on tight margins and just-in-time fulfilment, every injury chips away at resilience and profitability.

In this article, we explore the most common injuries in warehousing and manufacturing, break down their financial implications, and examine how automation is emerging as one of the most effective — and underused — tools in the injury prevention arsenal.

The Injury Landscape: What’s Going Wrong — and Where

Manufacturing and warehousing environments are inherently high-risk due to their physical nature, equipment density, and pace of operations. In the UK alone, over 60,000 non-fatal injuries were reported in manufacturing in the latest HSE statistics, with warehousing contributing tens of thousands more. These numbers likely underrepresent reality due to underreporting and cultural barriers around incident disclosure.

The Most Common Injury Types

Understanding the root causes of injury is the first step toward prevention. The following are the key categories dominating injury statistics:

1. Manual Handling Injuries (Musculoskeletal Disorders – MSDs)

Accounting for over a third of all reported workplace injuries in manufacturing, MSDs result from lifting, pulling, pushing, or repetitive tasks. Lower back injuries, tendonitis, and carpal tunnel syndrome are frequent consequences of poorly designed work processes.

2. Slips, Trips and Falls

Seemingly benign but frequently severe, these incidents often stem from cluttered walkways, fluid leaks, uneven flooring, or poor lighting. They’re also a leading cause of days lost from work, especially among older workers.

3. Machine Entanglements and Crush Injuries

Improper use of guarding equipment, hasty maintenance practices, and non-standard lockout/tagout procedures often result in hand, limb, or torso injuries. In high-volume manufacturing, even a momentary lapse in focus can have catastrophic consequences.

4. Struck by Moving Vehicles or Falling Objects

Forklifts and reach trucks contribute significantly to collision-related injuries. Equally, improperly stored pallets and unstable racking systems are common sources of falling-object trauma.

5. Fatigue-Related Errors

Though not always classified as injuries per se, fatigue-driven mistakes — especially during night shifts or extended peak seasons — can lead to a cascade of safety risks. Workers may ignore protocol, misjudge loads, or skip PPE.

Unpacking the Financial Toll

When injuries occur, the costs mount — often invisibly at first. Health & Safety professionals and HR leaders need to account not just for the direct costs (medical treatment, compensation), but the indirect and compounding losses that come in the aftermath.

Direct Costs: The Tip of the Iceberg

  • Medical expenses and rehabilitation: These can be significant, especially in cases involving long-term physiotherapy or surgery.
  • Workers’ Compensation and Employer Liability Claims: Compensation payouts can range from £5,000 for minor incidents to well over £100,000 for severe cases, including emotional distress and punitive damages.
  • Legal fees and litigation: If a safety breach is proven, companies may face drawn-out legal battles and HSE enforcement notices or prosecutions.

Indirect Costs: The Hidden Drain on Performance

  • Lost productivity: Injured workers often require time off, and replacements may not be trained to the same standard.
  • Downtime and disruptions: Investigations may require machinery shutdowns or temporary halts in production.
  • Increased insurance premiums: Companies with a track record of injuries often see year-on-year hikes in employer liability and public liability insurance.
  • Reputational damage: In a competitive contract environment, safety violations can cost more than money — they can cost future business.

A Quantifiable Impact

According to the UK HSE’s Cost to Britain of Workplace Injuries report:

The average cost to employers per non-fatal injury is £1,700, while serious incidents can range far higher. Cumulatively, the UK economy loses £18 billion annually due to work-related illness and injury.

Add to this the potential cost of failing customer audits, losing certifications, or facing civil suits — and the urgency becomes self-evident.

Automation as a Safety Strategy, Not Just a Productivity Play

For decades, automation has been promoted as a lever for operational efficiency. But increasingly, forward-thinking organisations are reframing automation as a safety-first investment — one that delivers ROI not just in output, but in lives, limbs, and liability avoided.

How Automation Reduces Risk

1. Eliminating Manual Lifting

Automated palletisers, robotic arms, and pick-and-place systems remove the need for humans to lift, twist, or bend repetitively. This directly reduces the leading cause of workplace injury: musculoskeletal strain.

2. Improving Consistency and Control

Unlike human workers, machines don’t fatigue, skip steps, or improvise. Automation ensures that dangerous processes — such as welding, sawing, or press forming — are executed with repeatable safety margins.

3. Separating Humans from Hazard Zones

By implementing robotic systems and AGVs in high-traffic areas, manufacturers can minimise pedestrian exposure to heavy vehicles or pinch points.

4. Real-Time Hazard Detection

Advanced automation includes sensor technology, computer vision, and AI that can flag potential dangers before incidents occur — whether it’s an overheating motor or a blocked emergency exit.

5. Reducing Fatigue and Human Error

By reallocating physically and mentally demanding tasks to machines, humans can focus on supervision, quality assurance, and exception handling — improving job satisfaction and retention.

Best Practices for Injury Prevention: A Holistic Framework

Even with the best technology, safety ultimately depends on culture, leadership, and consistency. Here’s a framework adopted by leading manufacturers:

1. Design for Safety from the Start

Involve health and safety officers during the procurement and layout stage of new equipment and automation projects. Avoid retrofitting safety after the fact.

2. Invest in Ongoing Training

Regular, role-specific safety training — reinforced through toolbox talks, digital learning platforms, and simulations — helps embed safe behaviours.

3. Digitise Safety Oversight

Deploy cloud-based safety dashboards that visualise live KPIs such as near misses, PPE compliance, and corrective actions — empowering teams to act proactively.

4. Incentivise Reporting and Transparency

Make it easy for staff to report safety concerns — and reward them for doing so. Anonymous reporting apps and “safety hero” initiatives can shift the culture from reactive to preventative.

5. Audit. Improve. Repeat.

Conduct monthly safety walkarounds, quarterly ergonomic assessments, and annual equipment audits. Use each to inform your continuous improvement roadmap.

Conclusion: Safety as Strategy

The manufacturing and warehousing sectors are under immense pressure to optimise — faster lead times, lower costs, tighter margins. But in the race to improve output, too many organisations overlook their most essential asset: their workforce.

Workplace injuries are not just accidents — they are signals. They reflect systemic gaps, missed opportunities, and underinvestment. And the cost of ignoring them is not just regulatory or reputational — it’s deeply operational.

Automation is not about replacing people — it’s about protecting them. By integrating intelligent automation with robust safety systems, leaders can build operations that are not only efficient but resilient, ethical, and future-proof.

Call us on 01223 499488 to discuss your automated palletising requirements.

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How to Significantly Improve Palletising Efficiency

Posted on August 6, 2025 by Granta

A Strategic Guide to Unlocking Productivity, Reducing Labour Dependency, and Future-Proofing Your End-of-Line Operations

In today’s high-pressure manufacturing and warehousing environment, palletising is far more than a simple end-of-line task—it is a critical process that directly impacts your operational throughput, labour efficiency, shipping costs, and customer satisfaction.

Yet, many businesses still operate with outdated, manual, or semi-automated palletising processes that restrict production scalability and increase cost per unit. If your palletising area is a bottleneck, your entire operation suffers. In this article we look at proven strategies to dramatically improve palletising efficiency—from robotic automation and pattern optimisation to software integration and predictive maintenance.

The Hidden Cost of Palletising Inefficiencies

In many factories, the palletising area receives little attention until something breaks or throughput drops below target. But ignoring palletising inefficiencies can cost your business:

  • End-of-line bottlenecks and reduced productivity
  • Increased manual labour costs and high staff turnover
  • Higher transport costs due to poor pallet utilisation
  • Frequent stoppages, stack collapses, and safety incidents

The good news? All of these issues are solvable. And with the right strategy, palletising can move from being a weak point to a competitive advantage.

1. Upgrade to Robotic Palletising: Consistency at Scale

Manual and semi-automatic palletising is labour-intensive, physically demanding, and prone to errors. Robotic palletising offers a scalable solution to these challenges.

Key Benefits of Robotic Palletising:

  • High-Speed Precision: Robotic arms can handle multiple picks per minute with extreme accuracy.
  • Zero Fatigue, 24/7 Operation: Robots don’t take breaks or call in sick, ensuring consistent throughput on every shift.
  • Safe and Ergonomic: Reduces musculoskeletal injuries and improved compliance with health and safety standards.
  • Multi-SKU Adaptability: Easily reprogrammed by factory staff to handle varying product sizes, shapes, and stacking patterns.

At Granta Automation, our robotic palletising systems are designed to integrate seamlessly with existing lines and can be scaled from single-line to multi-line operations. Whether you’re palletising cases, bags, bottles, or drums, robotic systems provide the repeatability and flexibility manual processes can’t match.

2. Intelligent Pallet Pattern Optimisation: Stack Smarter, Not Harder

Poorly optimised pallet patterns don’t just waste space—they also increase the risk of load collapse, increase shipping costs, and require more packaging materials. Advanced palletising software changes the game.

What Pattern Optimisation Can Do:

  • Maximise Pallet Density: Fit more product per pallet while maintaining balance and structural integrity.
  • Reduce Transport Costs: Fewer pallets mean fewer lorry loads and lower carbon emissions.
  • Improve Load Stability: Engineered patterns reduce tilting and shifting during transport.
  • Accelerate Changeovers: Pre-programmed patterns can be switched in seconds for different SKUs.

Using Granta’s easy programming software, you can programme and test stacking configurations in minutes, before production even begins—minimising risk and maximising output.

3. Seamless Line Integration: The Efficiency Multiplier

Palletising doesn’t happen in isolation. Your system’s true efficiency depends on how well it communicates with the upstream and downstream processes.

Full-System Integration Should Include:

  • Infeed Conveyors with Product Orientation Tools
  • Real-Time Synchronisation with Case Packers and Shrink Wrappers
  • Outfeed Conveyors Linked to Stretch Wrappers or AGVs

At Granta, we specialise in end-to-end automation, designing palletising systems that integrate seamlessly with your existing production equipment—so rather than simply adding a robot, you’re enhancing the performance and efficiency of your entire line.

4. Modular, Future-Proof Design: Build for What’s Next

In today’s market, agility is everything. A system that works today may fall short tomorrow if it lacks adaptability. That’s why modular design is a critical component of long-term palletising efficiency.

Advantages of Modular Palletising Cells:

  • Fast Reconfiguration: Adapt quickly to changing product lines or packaging formats.
  • Minimal Downtime for Upgrades: Add or remove modules without full system overhaul.
  • Expandable Layouts: Easily scale your operation as demand grows.

When we design a palletising solution at Granta, we build for today—but we also leave room for tomorrow. Whether you add SKUs, expand lines, or switch to new packaging types, your palletising system should evolve with you—not against you.

Make Palletising Your Competitive Advantage

Palletising is more than a box-stacking exercise—it’s a strategic lever for reducing cost, improving throughput, and unlocking the full value of your production line. Whether you’re dealing with labour shortages, rising order complexity, or aggressive delivery schedules, investing in efficient palletising is no longer optional—it’s essential.

At Granta Automation, we don’t just supply automation—we engineer complete palletising systems designed to fit your products, your space, and your future goals. From feasibility analysis to design, installation, and support, we provide turnkey solutions that deliver real results.

Ready to improve palletising efficiency in your facility?

Call us on 01223 499488, or request a free consultation today. Let us help you stack smarter, work faster, and build an operation that’s ready for whatever comes next.

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Which Cobot Palletiser System Is Best for My Application?

Posted on July 30, 2025 by Granta

In today’s fast-paced manufacturing environment, flexibility, efficiency, and scalability are critical for maintaining a competitive edge. As manufacturers seek smarter ways to automate labour-intensive processes, cobot palletisers have emerged as a powerful tool to streamline end-of-line operations.

Unlike traditional robotic palletisers, which are often fixed in place and require specialist programming knowledge, cobot palletising systems offer a far more agile solution. But with various technologies and suppliers in the market, the question many manufacturers are asking is: Which cobot palletiser system is best for my application?

Let’s take a closer look at one of the most versatile and user-friendly systems currently available: the Granta Automation cobot palletiser — a solution designed specifically for fast-moving, multi-line production environments.

Why a Cobot Palletiser?

Collaborative robots (cobots) are designed to operate safely alongside human workers without the need for extensive guarding or safety enclosures, making them ideal for manufacturing environments where space is limited and flexibility is essential. Their key advantage lies in built-in intelligent force sensing, which allows them to operate in collaborative mode — running at reduced speeds and stopping immediately if any unexpected force or contact is detected. When full safety measures are in place, and no-one is in the safe zone, the cobot can switch to industrial mode, operating at higher speeds for maximum efficiency.

Key Advantages of the Granta Cobot Palletiser

1. Portable – Move Between Production Lines with Ease

One of the most compelling benefits of the Granta cobot palletiser is its mobility. Unlike traditional systems that are bolted to the floor and dedicated to a single line, this cobot palletiser is mounted on a mobile frame, allowing it to be moved from one production line to another as needed.

This capability is ideal for facilities running multiple short-run product lines, seasonal goods, or low-volume, high-mix production. It means one system can serve multiple roles — reducing capital expenditure and increasing asset utilisation.

2. Rapid Reprogramming by Factory Staff – No Specialist Needed

In traditional automation setups, any change to box size, stacking pattern, or pallet configuration often requires an external technician or software engineer. That’s not the case here.

The Granta cobot palletiser is designed with operator-level usability in mind. Using an intuitive touchscreen interface, factory floor staff can reprogram the system in just a few minutes — no coding skills or robotic experience required.

Whether you’re changing box dimensions, updating stacking patterns, or switching between single or twin pallet configurations, the reprogramming process is streamlined and user-friendly. This significantly reduces downtime, increases agility, and enables lean manufacturing at scale.

3. Compact Footprint – Ideal for Space-Constrained Facilities

Floor space is a premium in most factories, especially in retrofit automation projects. The Granta cobot palletiser has been engineered with a minimal footprint, allowing it to operate in tight production environments without the need for major layout changes.

This makes it suitable for manufacturers who want to automate without a complete overhaul of their existing infrastructure. The compact design also means it can be easily repositioned or stored when not in use, making it an exceptionally flexible automation asset.

4. Safe, Collaborative Operation

Safety is built into the DNA of this cobot system. Equipped with force sensing and intelligent sensors, the palletiser can operate safely around people. It automatically stops if it encounters an obstruction or unintended contact, ensuring compliance with modern safety standards without the need for cumbersome guarding.

This also enables manufacturers to maintain a hybrid production environment, where people and machines work side by side — combining the strengths of both to maximise efficiency.

5. Future-Proof Your Automation Investment

Perhaps most importantly, the Granta cobot palletiser isn’t just a tool for today — it’s an investment in the future. Its flexibility, portability, and reprogrammability ensure it remains relevant even as your product mix, packaging formats, or factory layout evolve.

Whether you need to scale up, introduce new product lines, or meet new customer demands, the system can adapt with minimal cost or disruption. This makes it an ideal solution for businesses committed to continuous improvement and sustainable growth.

Is This the Right System for You?

If your production environment involves:

  • Multiple short-run or seasonal product lines
  • Frequent changes in box sizes or stacking patterns
  • Limited floor space or tight factory layouts
  • A need to automate without increasing reliance on external technicians

…then this cobot palletising system is an excellent fit.

Its combination of mobility, ease of use, and rapid reconfigurability make it one of the most flexible solutions available on the market. For manufacturers looking to maximise efficiency while retaining operational agility, it offers an ideal balance of capability and simplicity.

Learn More

To see how this cobot palletiser could fit into your specific production environment, visit:
👉 https://www.granta-automation.co.uk/types-of-automation/cobot-palletiser

If you’d like to discuss how Granta Automation can support your cobot integration contact us on 01223 499488 or helpline@granta-automation.co.uk.

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How to Elevate and Improve Operational Efficiency and Performance: A Practical Guide

Posted on July 30, 2025 by Granta

In today’s competitive industrial landscape, operational efficiency is no longer a secondary concern—it’s a strategic imperative. Rising costs, increasing customer expectations, and mounting supply chain complexities demand that businesses continuously scrutinise and refine the way they operate.

This article explores proven methods for evaluating and enhancing operational efficiency and performance across your business—whether you’re a lean-focused SME or a large-scale manufacturer managing complex supply chains.

Understanding Operational Efficiency

Operational efficiency refers to the ability of an organisation to deliver products or services using the least amount of resources possible—without compromising quality, safety, or service. It’s about doing more with less, but in a sustainable and scalable way.  But to improve something, you must first be able to measure it.

Defining and Tracking Key Performance Indicators (KPIs)

The foundation of any efficiency programme starts with the right metrics. Without clearly defined KPIs, efforts to improve performance can become reactive rather than strategic.

Consider KPIs such as:

  • Cycle time (how long it takes to complete a task or produce a product)
  • Cost per unit (total cost divided by total units produced)
  • Defect rates (number of defective units as a percentage of total output)
  • Downtime (machine or process non-operational time)
  • Customer satisfaction scores (indicative of quality and delivery reliability)

Establish a regular review cadence for these indicators. Visual dashboards and real-time reporting tools can make KPI tracking part of daily decision-making rather than a quarterly ritual.

Process Mapping: Making the Invisible Visible

Before you can improve a process, you must first understand it. Process mapping is a vital tool that gives a clear visual representation of how work flows through your organisation. By breaking down tasks, roles, inputs, and outputs, bottlenecks and redundancies quickly become apparent.

Look for:

  • Repeated hand-offs
  • Excessive approvals or manual inputs
  • Areas with high variability or inconsistency

Even well-established workflows often reveal surprising inefficiencies when examined with fresh eyes.

Applying Lean and Six Sigma Thinking

Once process inefficiencies are identified, Lean and Six Sigma methodologies provide a structured approach to eliminating waste and reducing variation.

The DMAIC framework (Define, Measure, Analyse, Improve, Control) is particularly effective for continuous improvement projects. It ensures changes are backed by data and embedded in daily operations—not just surface-level fixes.

Lean focuses on flow and waste elimination; Six Sigma hones in on quality and variation. When used together, they form a powerful toolkit for process optimisation.

Harnessing Automation and Smart Technologies

Technology is a critical enabler of efficiency—but only when it’s applied strategically.

Automation can:

  • Reduce manual handling
  • Eliminate human error
  • Increase consistency and throughput
  • Provide real-time visibility into production performance

From robotic material handling systems to fully integrated production lines, modern automation solutions are increasingly flexible and scalable.

Pairing automation with intelligent software platforms—such as Manufacturing Execution Systems (MES) or ERP integrations—can provide a single source of truth across operations. This allows faster decision-making and more agile response to change.

Empowering Your Workforce

Operational excellence doesn’t come from machines alone. People remain at the heart of any improvement effort.

Invest in:

  • Upskilling and cross-training
  • Regular performance reviews and feedback
  • Workshops that encourage problem-solving and innovation

When employees understand how their role contributes to overall performance—and are empowered to improve it—they become proactive drivers of change rather than passive participants.

Strategic Resource Allocation

Efficiency isn’t about pushing resources harder, but using them smarter.

Ask yourself:

  • Are the right people working on the right tasks?
  • Are machines operating at optimal capacity?
  • Are materials available when and where they’re needed?

Tools like Gantt charts, resource planning software, and automated scheduling can help ensure alignment between demand and capacity—minimising idle time and overextension alike.

Strengthening Supplier Collaboration

Suppliers play a direct role in your operational performance. Poor communication, delayed deliveries, or inconsistent quality can ripple across your production schedule.

Evaluate suppliers regularly on:

  • On-time delivery rates
  • Lead time reliability
  • Quality consistency
  • Responsiveness and service

Establishing open, data-led conversations with your suppliers often uncovers new opportunities for joint improvement or innovation.

Intelligent Inventory Management

Inventory is often seen as a buffer—but excess stock ties up capital, consumes space, and increases the risk of obsolescence.

Consider implementing:

  • Just-in-Time (JIT) strategies
  • ABC analysis for inventory classification
  • Forecasting tools to better match inventory with demand

Better inventory control not only boosts efficiency but also improves agility—allowing faster response to market shifts or customer demands.

Benchmarking Against the Best

How do you compare to the rest of the industry?

Benchmarking involves comparing your processes and performance against peers, competitors, or recognised best-in-class performers.

This doesn’t mean copying others blindly—but it can highlight areas where you lag behind, or identify practices worth adapting for your own context.

Tapping Into Customer Feedback

Ultimately, the customer is the judge of your operational effectiveness. Delays, defects, or poor service all reflect inefficiencies in your system.

Gather and analyse customer feedback regularly—via surveys, support logs, or direct conversations. Then loop these insights back into your continuous improvement efforts.

Remember: small changes that enhance customer satisfaction often yield internal productivity gains as well.

Cultivating a Culture of Continuous Improvement

Tools and tactics matter—but lasting efficiency gains come from cultural change.

Encourage your team to:

  • Identify problems and propose solutions
  • Share lessons learned from past projects
  • Celebrate wins—both large and small

A culture of improvement embeds accountability and curiosity into everyday operations. Over time, it creates an environment where change is embraced, not resisted.

Using Data as a Decision Driver

Today’s data analytics tools allow unprecedented visibility into operational performance. From real-time dashboards to advanced predictive models, data can help uncover hidden patterns and pre-empt potential issues.

Adopt tools that:

  • Consolidate data across departments
  • Enable drill-down analysis
  • Support custom reporting and alerts

The goal is to move from reactive troubleshooting to proactive, insight-led decision-making.

Managing Risk and Change Effectively

Every operation carries inherent risk—from equipment failure to labour shortages to regulatory shifts.

Building operational resilience involves:

  • Identifying critical failure points
  • Creating contingency plans
  • Regularly testing your responses

Integrating risk management into your daily operations can prevent minor issues from becoming costly disruptions.

Leading Improvement with Project Management Principles

Improvement initiatives require structure and ownership. Applying project management methodologies ensures that resources are aligned, timelines are met, and benefits are realised.

Tools such as Gantt charts, Kanban boards, and milestone tracking are invaluable when rolling out process improvements or technology changes.

Keeping Cost Control Front of Mind

Efficiency often equates to lower operating costs—but only when cost control is actively managed.

Establish cost control practices such as:

  • Activity-based costing
  • Variance analysis
  • Regular audits of overheads and waste

But remember: cost-cutting at the expense of quality or morale is rarely sustainable. Aim for smart savings that enhance—not hinder—long-term performance.

Conclusion: Efficiency as a Competitive Edge

Operational efficiency isn’t a one-time project—it’s a mindset, a set of tools, and a daily discipline. By continually assessing and improving how your organisation works, you unlock capacity, improve quality, and enhance customer value.

At Granta Automation, we help businesses design and implement automation solutions that directly support these goals—creating smarter, more agile manufacturing environments.

Explore our OEE Calculator and Basic Productivity Calculator to begin measuring your current efficiency and identify the next steps for improvement.

If you would like to know more about the Granta palletising systems or AMR/AGV systems, then please do get in touch on 01223 499488 or contact us at helpline@granta-automation.co.uk.  We will be very happy to help.

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The Advantages and Disadvantages of Robotic Automation in Manufacturing: A Practical Guide for UK Industry

Posted on July 30, 2025 by Granta
Advantages and Disadvantages of Robotic Automation

Robotic automation has long been associated with high-tech industries and multinational production lines, but in recent years, it has become increasingly accessible—and necessary—for manufacturers of all sizes. As supply chain pressures mount, labour shortages deepen, and demand for consistent, high-quality output grows, robotic automation is moving from an aspirational ideal to an operational imperative.

Yet with all its promise, automation is not without its challenges. Business leaders must consider more than just the technical feasibility. The decision to automate affects workflows, workforce planning, capital allocation, and long-term business strategy. And while the benefits can be significant, they’re not guaranteed without thoughtful planning and proper execution.

This guide explores the core advantages and disadvantages of robotic automation, helping manufacturers assess how, when, and where to deploy it for the greatest strategic gain.

Why Robotic Automation Is Gaining Ground in UK Manufacturing

The manufacturing landscape has shifted dramatically in the last decade. Rising energy costs, increasing customer expectations, and a shrinking pool of skilled workers have forced manufacturers to look inward for efficiency gains. Automation—especially robotic automation—offers a tangible way forward.

Modern robotic systems have evolved well beyond the fixed, hard-coded machines of the past. Today’s systems are intelligent, adaptable, and capable of integrating into existing production environments with minimal disruption. From high-speed pick-and-place arms to collaborative robots (cobots) that work safely alongside human operators, robotic automation offers a level of flexibility and scalability that suits a wide range of applications.

For most manufacturers, the question is no longer “Should we automate?” but rather “How do we automate in a way that makes the most sense for our business?”

Advantages of Robotic Automation

1. Enhanced Product Consistency and Repeatability

At the heart of robotic automation is one major promise: consistent output, regardless of volume or complexity. Robots follow precise programming and execute tasks identically every time. This eliminates human error and variation, especially in repetitive tasks such as assembly, cutting, sorting, and welding.

For sectors where quality control is critical—such as automotive, food and beverage, or electronics—this consistency significantly reduces waste, rework, and customer complaints. It also makes meeting ISO standards and traceability requirements much more straightforward.

2. Substantial Gains in Throughput and Productivity

Robots don’t require breaks, shift changes, or holidays. They can operate 24 hours a day, seven days a week, which allows manufacturers to scale production without a proportional increase in labour. When programmed and maintained correctly, robotic systems can dramatically increase cycle times, streamline bottlenecks, and support lean manufacturing principles.

In many cases, production lines that integrate automation experience a marked improvement in OEE (Overall Equipment Effectiveness), particularly through reductions in idle time and unplanned stoppages.

3. Safer, More Compliant Work Environments

Manual handling injuries, repetitive strain issues, and exposure to hazardous materials are perennial challenges in manufacturing. Robotic automation mitigates these risks by taking over the most dangerous or physically demanding tasks. From palletising heavy loads to handling high-temperature materials, robots can be deployed in ways that protect human health while ensuring compliance with health and safety regulations.

This isn’t just good ethics—it’s good business. Reducing accidents means fewer absences, fewer claims, and fewer regulatory headaches.

4. Flexibility to Scale and Adapt

Modern robotic systems are highly adaptable. Some are built with accessibility in mind, meaning they can be reprogrammed or reconfigured by production staff as production needs change. Movable robotic systems are also not on the market, allowing robotic systems to be transferred between production lines as the demand requires. This allows manufacturers to adapt quickly to new product lines, seasonal surges, or changes in demand—without having to start from scratch.

In a world where customer expectations increasingly demand agility and product customisation, this kind of operational flexibility can be a significant competitive advantage.

5. Workforce Upskilling and Strategic Deployment

One of the common misconceptions around automation is that it simply eliminates jobs. In reality, it often transforms them. When robots take on repetitive or low-skill tasks, human workers can be redeployed into higher-value roles—such as robot programming, quality control, data analysis, or system supervision.

With the right training and transition planning, robotic automation can become a platform for workforce development, rather than workforce reduction.

6. Long-Term Cost Efficiency

While automation involves a notable upfront investment, the long-term savings are substantial. Labour costs, waste, downtime, and quality defects are all reduced. Robots don’t require overtime pay, pensions, or recruitment efforts. They’re also not subject to fatigue or variation in output.

With typical ROI timeframes ranging from 12 to 36 months, depending on application, many manufacturers find that the financial justification for automation becomes stronger each year—especially in high-throughput environments or where margins are tight.

Disadvantages and Challenges of Robotic Automation

1. High Initial Capital Investment

There’s no avoiding it: robotic systems represent a significant capital outlay. From the cost of the equipment itself to integration, programming, safety guarding, and operator training, the total project budget can add up quickly. For smaller manufacturers or those operating with narrow margins, this can make automation seem out of reach—at least in the short term.

However, it’s essential to view this cost in context. Consider not just the price tag, but the long-term value created in terms of output, consistency, and scalability. Grant funding, leasing options, and hire options can also help reduce the barrier to entry and can often result in solutions that cost less than the pay back per month.

2. Integration Complexity

Retrofitting a robotic system into an existing production line isn’t always straightforward. Space constraints, legacy machinery, inconsistent upstream processes, and limited digital infrastructure can complicate the integration process. Planning is crucial.

Poor integration can negate the benefits of automation by creating new bottlenecks or causing compatibility issues. That’s why working with an experienced automation partner—who understands the full production lifecycle—is vital to achieving the right outcome.

3. Technical Skill Requirements and Change Management

Automated systems require new competencies—from programming and diagnostics to maintenance and data interpretation. Without investing in upskilling or hiring new talent, companies risk becoming dependent on external service providers, increasing downtime when issues arise. The key way to avoid this is to ensure any system you bring into your business has easy programming that anyone can use without advanced training.

Just as importantly, introducing robots into a previously manual environment requires careful change management. Staff may worry about job security or feel uncomfortable with new processes. Engaging the workforce early, providing reassurance, and offering training are all essential for a smooth transition.

4. Maintenance and Downtime Risks

Although robotic systems are highly reliable, they are not maintenance-free. Preventive maintenance schedules must be followed diligently to avoid unscheduled downtime. Replacement parts, diagnostic tools, and service support must all be considered as part of the total cost of ownership.

Without the right maintenance strategy, even a well-integrated robotic system can become a point of failure in an otherwise efficient production line.

Making the Right Choice for Your Business

Robotic automation is a strategic investment that demands alignment with your business model, operational challenges, and growth plans.

Ask the right questions:

  • Where are your current process inefficiencies?
  • What tasks are repetitive, hazardous, or prone to error?
  • How much downtime or waste do you experience—and at what cost?
  • Do you have the in-house capabilities to manage automation, or do you need a partner?

Robotic automation is at its most powerful when it solves a clear problem and unlocks measurable value. It’s not about automation for its own sake—it’s about making your operation more efficient, more resilient, and more competitive.

How Granta Automation Supports Manufacturers

At Granta Automation, we specialise in building robotic palletising systems that are designed to deliver results. Whether you’re looking to automate a single process, or you need a fully integrated production solution, we provide tailored, turnkey systems backed by real-world expertise.

Our approach starts with a conversation. We work with you to identify automation opportunities, quantify ROI, and design systems that suit your environment, not the other way around. From proof of concept through to installation, training, and ongoing support with very easy programming software, we’re with you every step of the way.

Ready to explore how robotic automation could transform your production line?
Get in touch with us today for a no-obligation consultation on 01223 499488 or helpline@granta-automation.co.uk, and discover how automated palletising can revolutionise your production line.

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Future-Proofing Your Manufacturing Line with Robotic Palletising

Posted on July 11, 2025 by Granta

Manufacturing is evolving at a faster pace than ever before. The combined pressure of global supply chain disruptions, increasing product complexity, labour shortages, and the relentless demand for faster throughput is pushing manufacturers toward smarter, more agile production strategies. In this high-stakes environment, companies that continue to rely on manual, outdated processes are at risk of falling irreversibly behind.

One area that has seen a rapid and impactful shift is end-of-line automation—specifically robotic palletising. Once seen as a luxury investment for large operations, robotic palletising is now a practical, scalable solution that delivers immediate ROI while paving the way for long-term competitiveness.

In this article, we’ll examine why robotic palletising is more than a tactical upgrade—it’s a strategic necessity. We’ll look at the rising demand for automation across the sector, how robotic palletising systems are designed for seamless integration and how automation equips manufacturers to adapt and thrive in a rapidly changing industrial landscape.

The Growing Demand for Automation in Manufacturing

Over the last decade, automation has shifted from being a tool of efficiency to a lifeline for continuity and growth. In a world where product mixes change rapidly, customer expectations for shorter lead times intensify, and access to skilled labour is increasingly constrained, manufacturers are being forced to rethink how they structure their production lines.

Robotic palletising offers a powerful solution to many of these challenges. It eliminates manual handling errors, reduces workplace injuries, enhances consistency in pallet formation, and can operate continuously with minimal supervision. With many plants operating multiple shifts to meet demand, having a system that doesn’t fatigue, doesn’t require breaks, and performs with unwavering precision becomes a clear competitive advantage.

Beyond efficiency, automation is becoming a prerequisite for meeting customer compliance requirements. Retailers and distributors are increasingly setting stricter standards for pallet quality, labelling accuracy, and load stability. Robotic palletisers help ensure that every pallet leaving your facility meets these standards without exception.

Global spending on industrial robots in the packaging and palletising sector has increased year on year, with SMEs now representing one of the fastest-growing segments in automation adoption. The message is clear: automation is no longer confined to mega-factories—it’s a vital asset for operations of every size.

Seamless Integration: From Legacy to Leading-Edge

One of the lingering myths around robotic palletising is that it’s disruptive to implement. In reality, modern palletising systems are designed to integrate quickly and cleanly with existing infrastructure—whether you’re working with legacy machinery or the latest production technology.

At the heart of this easy integration is system design. Robotic cells are now built with flexibility in mind: compact footprints, adjustable infeed and outfeed conveyor heights, and custom end-of-arm tooling ensure that they can slot into existing production lines with minimal reconfiguration. Many systems can be installed and commissioned within a matter of days, drastically reducing any potential downtime.

Communication between systems has also become significantly more seamless. Robotic palletisers can now ‘talk’ to upstream equipment (such as case erectors or labellers) and downstream logistics systems (like AGVs or stretch wrappers) with ease. This connectivity not only ensures smooth operation but also opens the door to real-time process synchronisation.

Furthermore, user-friendly interfaces such as Granta Automation’s easy programming software have replaced the complicated programming environments of the past. Today’s HMIs are designed for operators, not programmers. That means a shift supervisor can teach the robot a new product pattern or diagnose a fault in minutes—without calling in an engineer.

Agility Through Automation: Thriving Amid Change

In today’s climate, adaptability is more than a strategic advantage—it’s a survival skill. Manufacturers are expected to pivot quickly in response to everything from market fluctuations to global crises. Whether it’s a sudden change in packaging regulations, an urgent shift in product mix, or a rapid scale-up due to new contracts, flexibility is key.

Robotic palletising gives manufacturers the ability to respond without overhauling their entire production line. For example, changes in SKU dimensions can managed simply with the easy programming software from Granta Automation.  Anyone can reprogram the palletiser for new product sizes or stack patterns within just a matter of minute. A surge in output can be absorbed by running the robot longer hours without compromising accuracy. Even layout reconfigurations—such as moving a line to accommodate a new machine—can be achieved more easily when your palletising is modular and mobile.

In addition, automation helps companies remain compliant and forward-thinking. As environmental and sustainability regulations tighten, companies are being asked to use lighter, more recyclable materials—which often behave differently during stacking. Robotic palletisers equipped with smart sensors and adaptive grippers can handle these delicate loads better than manual operators or older fixed automation systems.

And finally, consider the impact on your workforce. While automation reduces the need for repetitive manual labour, it also elevates the roles of existing staff. Operators become system supervisors, responsible for optimisation and oversight, rather than physical execution. This shift not only improves morale and retention but also fosters a culture of continuous improvement.

Conclusion: A Strategic Imperative, Not a Technical Upgrade

As the manufacturing landscape becomes more complex and demanding, the need for smart, scalable solutions is undeniable. Robotic palletising addresses immediate operational pressures while delivering a foundation for long-term agility and scalable growth.

It’s more than a productivity tool—it’s a strategic asset that empowers manufacturers to future-proof their operations. From seamless integration to adaptable performance, robotic palletising is transforming how factories run, how teams work, and how businesses compete.

For those ready to lead, the time to automate is now. Contact us today for a quote on 01223 499488 or email helpline@granta-automation.co.uk, and discover how automated palletising can revolutionise your manufacturing process.

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Why Operational Efficiency Is the #1 Competitive Advantage in Manufacturing

Posted on July 10, 2025 by Granta

In an industry defined by margins, milliseconds, and materials, efficiency is no longer a best practice — it’s the basis of survival.

For decades, manufacturers have sought competitive advantages in scale, location, and labour cost. But the 21st century has shifted the goalposts. In today’s hyper-competitive, globally connected, and unpredictably disrupted markets, the only sustainable edge is operational efficiency.

The most successful manufacturers don’t necessarily spend more. They don’t always own the biggest plants or employ the largest workforces. But what they do have — what consistently sets them apart — is the ability to do more with less, faster, and with higher precision.

Why Efficiency Matters More Than Ever

In 2025, the pressures on manufacturers are unprecedented:

  • Global volatility: Supply chain shocks, energy fluctuations, geopolitical instability, and pandemics have forced a rethink of just-in-time logistics and offshore dependencies.
  • Labour shortages: Skilled trades and experienced operators are increasingly scarce. Competition for talent is fierce. Retention is fragile.
  • Customisation demand: Clients expect shorter lead times, greater flexibility, and personalised products — without cost increases.
  • Sustainability mandates: ESG pressures are driving efficiency not just as a financial necessity, but as an ethical imperative.

Every inefficiency — a slow tool change, an outdated scheduling system, a non-integrated data source — represents a silent tax on profitability. And the compounding cost of this inefficiency is enormous.

It is estimated that the average manufacturing plant operates at just 60-70% of its maximum efficiency. The remaining 30-40% is opportunity — or, for the laggards, existential risk.

What the Best Manufacturers Do Differently

Leading manufacturers treat efficiency not as a KPI, but as a company-wide philosophy. Here’s what sets them apart:

1. Process Discipline at Every Level

Top-performing plants have one thing in common: standardised, repeatable processes that leave little to chance. Every task, from raw material intake to final packaging, is documented, time-stamped, and monitored. Variability is identified and eliminated.

But standardisation doesn’t mean rigidity. These manufacturers build flexibility into their operations, allowing them to shift between products or production volumes quickly, without losing control over cost or quality.

2. Empowered Frontline Teams

Modern efficiency isn’t driven solely from the boardroom — it’s shaped by the people on the floor. Operators in high-efficiency environments are trained to recognise waste, stop production when issues arise, and contribute to process improvements.

This is where Lean meets culture: systems like daily Gemba walks, visual dashboards, and autonomous maintenance empower teams to act fast and solve problems early.

3. Data-Driven Decision Making

Gut feel no longer cuts it. High performers capture real-time data from machines, lines, operators, and sensors — and use it to guide decisions. KPIs are tracked in real time, not weekly. Downtime is analysed within minutes, not after shift reports. And continuous improvement becomes measurable, not anecdotal.

A plant that knows its OEE in real-time — and can pinpoint the reason for each efficiency loss — is already miles ahead.

Technology as a Force Multiplier

Efficiency no longer means “doing the same things faster.” It means redefining how things are done — often with the help of technology.

Industry 4.0: Turning Insight into Output

The fusion of operational technology (OT) and information technology (IT) has unlocked the smart factory.

  • IoT sensors now provide second-by-second feedback from equipment — enabling predictive maintenance and eliminating unplanned downtime.
  • AI and machine learning crunch production data to find hidden inefficiencies, optimise scheduling, and forecast machine failure.
  • Digital twins allow manufacturers to model new production layouts or process changes without disrupting operations.
  • Cloud-based MES systems integrate ERP, supply chain, and shop floor systems — creating a seamless, real-time view of operations.
  • Automation solutions such as robotic palletisers streamline repetitive end-of-line tasks, freeing up skilled labour and reducing cycle time — a small change that can yield significant efficiency gains over thousands of shifts.

Lean + Tech = Smart Efficiency

Technology isn’t a replacement for Lean thinking — it’s an amplifier. Lean gives manufacturers the discipline and mindset to eliminate waste. Technology makes that discipline scalable and repeatable. It enables leaders to:

  • See deviations as they happen
  • Identify trends across shifts or sites
  • Capture tribal knowledge before it walks out the door
  • Simulate changes before investing capital

How to Optimise Production Processes: A Proven Framework

Whether you’re running a single plant or managing operations across global sites, the journey toward efficiency follows a clear trajectory.

Step 1: Baseline Performance

Begin with visibility. What is your current OEE? How much downtime is truly unplanned? Where are materials wasted or labour underutilised?

Use value stream mapping, spaghetti diagrams, and time-motion studies. Establish a data-driven baseline before rushing into changes.

Step 2: Prioritise Bottlenecks and High-Cost Areas

You can’t fix everything at once. Focus on areas that impact throughput, scrap, energy usage, or machine uptime. Identify “hidden factories” — workarounds or rework loops that silently erode productivity.

Prioritisation tools like Pareto analysis and 5 Whys help focus limited resources.

Step 3: Digitise for Insight

Install monitoring systems on legacy equipment. Tie manual stations into digital forms. Start with low-code platforms or plug-and-play IIoT devices. Digitisation doesn’t have to mean full automation — it just means turning data into action.

Ensure KPIs are visible to everyone. Operators should see how their work contributes to daily goals.

Step 4: Standardise Workflows and Train Relentlessly

Introduce standard operating procedures (SOPs) for all high-variability tasks. Invest in cross-training. Use visual work instructions, QR-coded manuals, and digital checklists to reduce errors and increase consistency.

Make training continuous — not just for onboarding.

Step 5: Establish a Culture of Kaisen

Efficiency is a daily habit, not a one-off project. Encourage feedback, reward improvement suggestions, and close the loop by implementing operator-driven ideas.

Regular performance reviews, weekly improvement huddles, and recognition programs go a long way in sustaining momentum.

From Efficiency to Market Leadership

Consider this: two manufacturers produce the same product. One delivers it in 2 days with a 1% defect rate. The other in 5 days, with 4% defects, at 8% higher cost.

Which one will win the next contract? Which one will scale profitably? Which one will adapt to the next supply chain shock?

The most efficient manufacturers don’t just produce better — they compete better. They respond faster to change. They reinvest savings into innovation. And they attract customers who value reliability and agility.

Efficiency is the ultimate competitive advantage. It touches everything: output, cost, quality, morale, and customer satisfaction. Operational efficiency is not a destination — it’s a discipline. In today’s market, it’s also a differentiator that cannot be faked or fast-tracked. For operations leaders and plant managers, the mandate is clear: move faster, work smarter, reduce waste, and empower people. The tools are ready. The frameworks are proven. And the winners will be those who treat efficiency not as a quarterly target — but as the foundation for long-term dominance.

If you would like to know more about the Granta palletising systems or AMR/AGV systems and the efficiencies they can bring, then please do get in touch on 01223 499488 or contact us at helpline@granta-automation.co.uk.  We will be very happy to help.

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What Are Gemba Walks — And Why They Matter Now More Than Ever

Posted on July 9, 2025 by Granta

In high-performing manufacturing environments, true operational insight doesn’t come from a dashboard—it comes from the floor. That’s the principle behind Gemba walks, a foundational Lean practice that has become increasingly vital in modern industrial operations.

The Meaning Behind “Gemba”

Gemba is a Japanese term meaning “the real place.” In a manufacturing context, this is the shop floor—the production line, the maintenance bay, the loading dock. It’s where products are made, value is created, and problems actually occur.

A Gemba walk is a structured, purposeful walk through the workplace by leaders, engineers, or supervisors to observe operations firsthand. It is not a tour. It is not a performance evaluation. It is a deliberate exercise in seeing, listening, and understanding.

The Purpose of Gemba Walks: Why They’re More Than Just a Walkaround

In manufacturing, the fastest path to inefficiency is decision-making disconnected from reality. Gemba walks address this by enabling leaders to:

  • Observe actual processes in real-time, not filtered through reports or screens
  • Engage directly with frontline employees to gain unfiltered insights
  • Identify waste, friction, and inefficiencies that go unnoticed in standard metrics
  • Reinforce a culture of continuous improvement by demonstrating leadership involvement

“Go see, ask why, show respect.” — This Lean mantra captures the spirit of a Gemba walk. It’s not about managing from a distance; it’s about leading from proximity.

How Effective Gemba Walks Work

While every Gemba walk will differ based on goals, the best are structured, intentional, and recurring. Here’s how it’s typically done:

  1. Define the Focus
    Don’t wander aimlessly. Choose an objective—safety, quality, downtime, changeover efficiency, standard work adherence, etc.
  2. Go to the Gemba
    Visit the site where value is created. This could be the shop floor, warehouse, machine station, or even a digital operations room.
  3. Observe Processes, Not Just People
    Watch the workflow. Is there motion waste? Is material staging efficient? Are operators forced to wait or rework?
  4. Engage Operators Thoughtfully
    Speak with team members. Ask open-ended questions like:
    • “What gets in the way of doing your job more efficiently?”
    • “If you could change one thing in this process, what would it be?”
    • “What’s the most common issue you see here?”

The goal isn’t to criticize—but to listen without judgement.

  1. Document Observations, Not Just Problems
    Record everything: observed delays, excessive walking, tool searches, unclear SOPs, inventory pile-ups. But also document what’s working well.
  2. Follow Up and Close the Loop
    A Gemba walk without action is worse than no walk at all. Reflect, analyse root causes, and most importantly—return to those involved with feedback or next steps.

The Strategic Value of Gemba Walks

While Gemba walks may seem tactical, their strategic impact is profound:

  • They surface hidden inefficiencies—like waiting time, excess motion, and communication delays—that traditional KPIs often miss.
  • They help bridge the gap between leadership and execution, building trust across all levels of the organization.
  • They reinforce accountability and ownership at the shop-floor level.
  • They reveal misalignments between standard operating procedures (SOPs) and real-world practices—giving you opportunities to revise, retrain, or improve.

In high-performance plants, Gemba walks are a daily discipline—not a quarterly exercise. They serve as the bedrock for Lean transformation, operator engagement, and long-term cultural change.

Gemba Walks in the Digital Age

Today’s smart factories are integrating digital tools into traditional Gemba walks:

  • Mobile devices allow leaders to log issues or photos on the spot.
  • Real-time dashboards enable comparison between what’s observed and what’s being reported.
  • Digital Gemba tools let distributed teams conduct hybrid walk-throughs, combining on-site and remote observation with virtual collaboration.

But even with these tools, the principle remains unchanged: go to where the value is created, and see for yourself.

In a world where leadership is often detached from day-to-day operations, Gemba walks are a simple, powerful way to stay grounded in reality. They drive alignment. They uncover what spreadsheets can’t. And they turn leadership into a visible, respected force for positive change. In the pursuit of operational excellence, Gemba walks are no longer optional. They are essential.

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How Fast Can My Cobot Run Without Guarding?

Posted on June 18, 2025 by Granta

When integrating collaborative robots (cobots) into production lines, a common and crucial question arises: How fast can my cobot safely operate without physical guarding? The answer hinges on comprehensive risk assessments, adherence to industry standards such as ISO 10218-2 and ISO/TS 15066, and the implementation of appropriate safety measures.

Understanding Safety Requirements

ISO 10218-2, the international standard for industrial robots, does not require physical guarding for cobots but mandates a thorough risk assessment to guarantee safe operation. Cobots come equipped with inherent safety features—such as force and speed limiting controls—that can permit unguarded operation, but only when specific conditions are met.

ISO/TS 15066 complements this by defining precise force and pressure thresholds to ensure safe human-robot interaction. These limits vary depending on the body part involved, recognizing that some areas are more vulnerable to injury:

  • Shoulder impact: up to 150 Newtons (N)
  • Forearm impact: approximately 50 N
  • Head or hand impact: as low as 10–20 N due to increased sensitivity

For a cobot operating in collaborative mode, staying within these force limits is essential to prevent injury.

Running a Cobot Without Guarding

The most straightforward approach to running a cobot without physical guarding is to limit its speed, ensuring that the forces exerted remain within safe boundaries.

  • Typical industrial robots operate at speeds up to 2,000 mm/s in non-collaborative modes.
  • In collaborative mode, ISO/TS 15066 recommends speeds of 250 mm/s (0.25 m/s) or less to meet safe force requirements, although a risk assessment might permit higher speeds depending on the specific application.
  • Practically, if a robot normally processes around 10 boxes per minute at full speed, running in collaborative mode might reduce throughput to roughly 1–1.5 boxes per minute, depending on risk factors and payload.

This speed reduction approach ensures compliance without the necessity for additional physical safety equipment. However, if faster operation is needed, other safety solutions must be explored.

Running Faster Without Physical Guarding

To increase operating speeds without resorting to traditional guarding, manufacturers can integrate safety technologies such as light curtains and area scanners:

  • Light Curtains act as virtual safety barriers, automatically slowing or stopping the cobot when someone crosses the beam. Proper safety distance calculations are crucial to maintain worker safety.
  • Area Scanners detect personnel approaching the work cell and dynamically adjust cobot speed or halt operations as needed. Their installation requires precise positioning and compliance with Performance Level d (PLd) safety standards.

While these technologies eliminate the need for solid physical barriers, they add complexity to system layout, safety distance management, and control programming.

Final Thoughts

A cobot can indeed operate without guarding, but with important limitations:

  • In fully collaborative mode, the cobot’s speed must be significantly reduced to comply with ISO/TS 15066 force limits.
  • Light curtains and area scanners provide options for higher speeds without physical guarding but require precise safety measures.
  • Comprehensive risk assessments are essential to balance safety, productivity, and regulatory compliance.

By carefully evaluating your specific application and following the guidelines set by ISO 10218-2 and ISO/TS 15066, you can achieve an optimal balance between efficiency and safety. If you’d like to discuss how Granta Automation can support your cobot integration contact us on 01223 499488 or helpline@granta-automation.co.uk.

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